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Multi-Material Metal Casting: Metallurgically Bonding Aluminum to Ferrous Inserts

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Multi-Material Metal Casting: Metallurgically Bonding Aluminum to Ferrous Inserts Multi-Material Metal Casting: Metallurgically Bonding Aluminum to Ferrous Inserts by Carl Soderhjelm submitted to the Faculty in partial fulfillment of the requirements for the degree of Doctor of Philosophy in Materials Science and Engineering at the Worcester Polytechnic Institute April 2017 APPROVED: _______________________________ Diran Apelian Alcoa-Howmet Professor of Engineering Thesis Advisor _______________________________ Richard Sisson George Fuller Professor of Mechanical Engineering Materials Science and Engineering Program Director Table of Contents Abstract ............................................................................................................................................................................... 3 Acknowledgements ......................................................................................................................................................... 4 Executive Summary......................................................................................................................................................... 5 1. Motivation .............................................................................................................................. 5 2. Bonding during Multi-Material Metal Casting ....................................................................... 5 2.1. Mechanical Bond ......................................................................................................................................... 5 2.2. Metallurgical Bond ...................................................................................................................................... 6 3. Why Metallurgical Bond? ....................................................................................................... 7 4. Problem Statement ................................................................................................................ 7 4.1. Challenges ...................................................................................................................................................... 7 5. Approach ............................................................................................................................... 8 6. Experimental Work .............................................................................................................. 9 6.1 Liquid-solid interaction between mild steel, A356 and 390 ............................................................ 9 6.2 The influence of silicon during liquid-solid diffusion of aluminum and iron ......................... 10 6.3 Effect of thermal treatments on the metallurgical bond ................................................................. 10 6.4 Effect of coatings on the metallurgical bond formation ................................................................. 11 7. Conclusions .......................................................................................................................... 11 7.1. A Practical Guide to Multi-Material Metal Casting ....................................................................... 13 8. Recommendations for Future Work ................................................................................. 14 Appendix A – Literature Review ............................................................................................................................. 15 Appendix B – Liquid-solid interaction between mild steel and A356 and 390 ......................................... 44 Appendix C – The influence of silicon during liquid-solid diffusion of aluminum and iron ................ 50 Appendix D – Effect of thermal treatments on the metallurgical bond ........................................................ 75 Appendix E – Effect of coatings on the metallurgical bond formation ........................................................ 94 Appendix F – A Practical Guide to Multi-Material Metal Casting ............................................................. 112 2 Abstract Properties of cast aluminum components can be improved by strategically placing ferrous inserts to locally improve properties such as wear resistance and stiffness. A cost-effective production method is to cast-in the insert using the solidification of the molten aluminum as a joining method. Metallurgically bonding between the metals could potentially improve both load and heat transfer across the interface. The metallurgical bond between the steel and the aluminum has to be strong enough to withstand stresses related to solidification, residual stresses, thermal expansion stresses, and all other stresses coupled with the use of the component. Formation of a continuous defect free bond is inhibited by the wetting behavior of aluminum and is governed by a diffusion process which requires both energy and time. Due to the diffusional nature of the bond growth in combination with post manufacturing heat treatments defects such as Kirkendall voids can form. The effect of aluminum alloying elements during liquid-solid bond formation in regards to microstructural changes and growth kinetics has been described. A timeframe for defect formation during heat treatments as well as microstructural changes has been established. The effect of low melting point coatings (zinc and tin) on the nucleation of the metallurgical bond has been studied as well the use of a titanium coating for microstructural modification. A set of guidelines for successful metallurgical bonding during multi-material metal casting has also been constructed. 3 Acknowledgements First and foremost, I want to express my sincere gratitude to my advisor Diran Apelian. His guidance kept me focused, his encouragement kept me persistent, his trust allowed me to learn from my mistakes, and his input inspired critical thinking which truly raised the quality of my work. As a friend, colleague, and advisee, I truly appreciate all our stimulating conversations during my time as a student at WPI, and they have been invaluable for the completion of this thesis. I also wish to thank Prof. Sisson, Prof. Makhlouf, Prof. Brody, and Prof. Mishra for their help throughout this time, be it in the classroom or during conversations their eagerness to answers to questions or offer advise helped progress this thesis. I want to thank the ACRC and its consortium members for the opportunity for me to work as a research assistant on the Multi-Material Metal Casting project. I specifically want to thank Lin Zhang, Adam Kopper, Kevin Anderson, and Jose Talamantes-Silva for their activity and many inputs during our focus group meetings. Thank you, Christof Heisser, Jim Lagrant, Brian Began, Vijay Alreja, Randy Beals, Tim Kaiser, and Doug Hamilton for your support during this project. The Metal Processing Institute is an inspiring place which would not be what it is without Carol Garofoli, Renée Brodeur, Maureen Plunkett, and Libo Wang. Thank you for all of your help, assistance, and friendships. I would also like to thank Rita Shilansky for her assistance and help. I have had much help during my time as a PhD student at WPI by students that have worked with me. The over 650 samples made, that has contributed to my understanding and knowledge in this thesis, in one way or another, was partly contributed by the following; the Masters’ student Federico Canali, the MQP team Alino Te, Rachel Harrison, Scott Olson, and the Masters’ student Chiara Bertuccioli. A thank you to all of you, I had a lot of fun working with you, and I made great friends. I have a lot of great friends and colleagues here at MPI and WPI that have been great for endless discussions and much-appreciated distractions which made my time here unforgettable. Among others, thank you; Aaron, Inigo, Sean, Shaymus, Theo, Yangyang, Eunkyung, Danielle, Baillie, Anthony, and Yuwei! And of course all other friends I have met during my time as a student at WPI. I would also like to take the opportunity to thank all of my brothers back at home who made my vacations all the more enjoyable. It should also be mentioned that I would not be here if it were not for the unconditional support of my parents and my sisters. My parent's hard work in making me who I am gave me the opportunity to work with something I love. Lastly, but most importantly, I thank my wife, Pamela, for her love, patience, understanding, and encouragement in this endeavor. Without her support, help and confidence in me this would not be possible. 4 Executive Summary 1. Motivation The increasing temperatures in the atmosphere have sparked a race to reduce the carbon dioxide footprint of our way of life. To accomplish this in the required timeframe new regulations are pushing the automotive industry to reduce the CO2 emissions of motor vehicles. To improve efficiency of a motor vehicle, three principal strategies can be employed; • Weight Reduction • Improving Powertrain Efficiency • Reducing Friction Reducing weight without compromising safety and comfort is generally achieved by moving from a heavier material to a lighter material to the extent for which it is both financially and technically viable. The Carnot cycle states that to improve the efficiency of the engine, it need to operate at higher temperatures and pressures. The friction of the car towards the environment can be improved by optimizing the aerodynamics as well as reducing the friction between the tires and the ground. For many of the metal components, weight reduction can be achieved by switching from ferrous alloys
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